5000kN Computer-Controlled Electro-Hydraulic Servo Horizontal Tensile Testing Machine

Product Name: 5000kN Computer-Controlled Electro-Hydraulic Servo Horizontal Tensile Testing Machine

Technical Proposal

I. Equipment Overview

The 5000kN Computer-Controlled Electro-Hydraulic Servo Horizontal Tension Testing Machine is a high-precision testing device suitable for tensile tests on conductors, wire ropes, power fittings, safety belts, porcelain insulators, composite insulators, fasteners, anchor chains, structural components, and similar specimens.

With the appropriate fixtures, it can perform static mechanical property tests and analysis on both metallic and non-metallic materials (including composites), such as tensile, compression, load holding, and reciprocating tests. It supports closed-loop control modes of stress, strain, and displacement. The system can automatically calculate parameters such as maximum test force, breaking force, upper and lower yield points, yield strength, tensile strength, elongation stress, elongation rate, and elastic modulus as required.

The machine also supports tests such as constant elongation stress and constant stress elongation, with the ability to print test reports and curves including the above parameters at any time.

The WLW series Computer-Controlled Electro-Hydraulic Servo Horizontal Tension Testing Machine developed by our company features stable loading rate, high load-holding accuracy, precise test data, large tensile space, wide specimen adaptability, and convenient fixture replacement. Customization of tensile space, piston stroke, pin structure, and clamping form is available to meet specific testing requirements.

II. Equipment Components

5000kN Hydraulic Cylinder Assembly – 1 set

5000kN Main Frame Assembly – 1 set

5000kN Reaction Frame Assembly – 1 set

5000kN Movable Clamping Carriage (remotely movable) – 1 set

5000kN High-Precision Load Sensor – 1 unit

5000-line Draw Wire Displacement Encoder – 1 unit

Static Test Controller – 1 set

Computer Control Software – 1 set

Intelligent Servo Hydraulic Source (with energy-saving servo motor, imported gear pump, and servo valve) – 1 set

Electric Drive System – 1 set

HP Printer – 1 unit

Computer: ASUS mainstream configuration – 1 unit

Hydraulic Clamping Jaw Assembly (semi-open type) – 1 set

III. Fixture Jaws (Jaw length no less than 250mm)

Flat jaws for plate specimens: clamping ranges 20–50 mm and 50–80 mm – 1 set each

Round jaws for bar specimens: clamping ranges φ20–50 mm and φ50–80 mm – 1 set each

U-type hanging fixture – 1 set

IV. Product Standards

GB/T 16826: Electro-Hydraulic Servo Universal Testing Machines

GB/T 2611-2007: General Technical Requirements for Testing Machines

JB/T 6146-2007: Extensometer Technical Conditions

GB/T 22066-2008: Evaluation of Computer Data Acquisition Systems for Static Uniaxial Testing Machines

GB/T 13634-2008: Calibration of Standard Force Measuring Instruments for Uniaxial Testing Machines

GB/T 6825.1: Inspection of Static Uniaxial Testing Machines – Part 1: Force Measurement Systems for Tension and/or Compression Testing Machines

GB/T 12160-2002: Calibration of Extensometers for Uniaxial Testing Machines

JJG 139-2014: Verification Regulation of Tension, Compression, and Universal Testing Machines

JJG 1063-2010: Electro-Hydraulic Servo Universal Testing Machines

Main Test Standards:

GB/T 228.1-2010: Metallic Materials – Tensile Testing – Part 1: Method of Test

GB/T 8358-2014: Steel Wire Ropes – Method for Determination of Actual Breaking Force

GB/T 3098.1-2010: Mechanical Properties of Fasteners – Bolts, Screws, and Studs

NB/T 31082-2016: High-Strength Bolt Assemblies for Wind Turbine Tower Structures

V. Main Technical Parameters and Performance Requirements

Machine Type: Horizontal (self-reaction frame structure with online force calibration)

Maximum Test Force: 5000kN

Testing Machine Grade: Grade 1

Force Measurement Range: 1%–100% FS (full-range, continuous measurement without gear shift)

Relative Error of Force Indication: ±1%

Force Resolution: 1/500,000 of full scale, minimum increment 4N

Maximum Piston Stroke: 500 mm

Displacement Measurement Range: 0–500 mm

Relative Error of Displacement Indication: ±1% or 0.01 mm

Loading Speed: 0.5–50 mm/min, steplessly adjustable

Distance Between Jaws: 0–12,000 mm (adjustable in 500 mm steps)

Pin Adjustment Interval: 500 mm

Pin Structure: Manual

Beam Movement: Automatic adjustment, adjustable in the range of 0.5–2.0 m

Mainframe Dimensions (approx.): 18,000 × 1,900 × 1,200 mm

Speed Control: Continuous and constant force loading (adjustable depending on max load)

Constant Load Accuracy: ±1% F.S

Control Mode: Electro-hydraulic servo control (intelligent oil source with silent loading)

Overload protection and emergency stop functions

Automatic data acquisition, processing, display, storage, deletion, printing, curve plotting with auto-scaling, and test report generation

Automatic calculation of initial modulus, final modulus, tensile strength, upper yield strength, lower yield strength, maximum force elongation, and other performance indices

Equipped with safety protection devices: overload protection, anti-instability system, and manual flip safety guard

Safety features include limit stops and overload protection to ensure the safety of personnel and equipment

Good maintainability with convenient maintenance and service

Tail-end fixed support with manual fine adjustment mechanism for easy specimen installation/removal

VI. General Description

The 5000kN Computer-Controlled Horizontal Tension Testing Machine primarily consists of the main frame, intelligent servo hydraulic source, control console, fixtures and accessories, and test monitoring system.

1. Overview of the 5000kN Loading Structure (Main Frame)

The main frame of the 5000kN loading device consists of the 5000kN static hydraulic cylinder assembly, bed guide rails, 5000kN cylinder reaction frame, gripping assembly, openable steel mesh safety shield assembly, pin assembly, and cylinder mounting base.

The effective test gauge length is 500 mm, the opening width is 850 mm, and the actuator stroke is 500 mm.

(1) Main Frame Structure

The guide rails and cylinder seat are made of welded steel plates and cast steel components, which undergo stress relief treatment to ensure the required rigidity of the main frame. Rails are installed on the inner sides of the guide structure to allow smooth movement of the movable tailstock carriage along the track.

The load-bearing frame is integrally welded from thick steel plates using Q235 steel. The advantages of this integral structure include:

Avoiding deviations caused by secondary assembly

Improving resistance to vibration by preventing relative motion between separate components

Minimizing deformation with the rigidity of thick-plate welded structure

(2) Hydraulic Cylinder Loading Assembly

The loading assembly adopts a four-column reaction frame structure formed by two carriages and a cylinder base, which provides the loading force for the entire system. It includes the loading end, hydraulic cylinder assembly, measuring components (load sensor and accessories), reaction beam, and tension rods.

Compared to two-column structures, this force-bearing design is more reasonable and reliable, avoiding test errors caused by frame deformation and improving accuracy. The loading end, tension rods, and reaction beam form the hydraulic cylinder reaction frame, which is used to calibrate the cylinder force. The measuring unit is used to record the applied force. The entire hydraulic loading assembly is mounted on the bed frame.

The gripping jaws and reaction beam are made of cast ZG450 steel; the cylinder base is welded from Q235 steel; the tension rods of the reaction frame are made of 45# steel. The main servo hydraulic cylinder operates in single-cylinder, double-acting mode. High-quality seals are used, and the cylinder tube and piston are made of high-strength, wear-resistant materials. High-pressure hoses ensure precise, leak-free operation of the cylinder.

Structure of the Hydraulic Cylinder Reaction Frame Loading End

The compression space refers to the space between the loading end of the main frame and the cylinder body, with a compression range of 0–500 mm. (If larger compression spaces or adjustable ranges are required, customization is available beyond 500 mm.)

Force Analysis at the Loading End

(Details of analysis, if applicable, to be inserted here.)

Rigid Deformation at the Loading End

The fixed tailstock is normally connected to the machine bed via a pin. When not testing, the pin can be removed, allowing the fixed tailstock to move. The tailstock carriage is driven along the guide rails by a motor connected to a belt and pulley mechanism.

The tailstock carriage is made of cast steel (ZG310-570), and the pins are made of 40Cr with quenching and heat treatment for durability.

Tailstock Gripping End Structure

Manual Fine-Tuning Mechanism of the Fixed Tailstock

The gripping end uses a jaw-type structure, compatible with embedded bolt tensile fixtures or pin-type tensile fixtures, offering excellent versatility. (Other fixture types can also be customized according to the actual testing needs.)

The pins are made from alloy steel 40Cr. After quenching and heat treatment, the large-diameter 40Cr alloy steel can effectively withstand the shearing force from the main unit, ensuring operational safety, reliability, and a longer service life.

Rigid Deformation of the Gripping End

The gripping mechanism of the horizontal tension testing machine uses a hydraulic wedge-type clamping method. This method has been widely and successfully applied by our company and ensures reliable specimen clamping.

To ensure the coaxiality of the gripping jaws on the loading end, it is determined by the positional tolerance between the hydraulic cylinder mounting base and the positioning of the loading cylinder. Since the loading jaw and the cylinder form part of a reaction frame, this design ensures that the jaw's center aligns precisely with the center of the machine, and also defines the jaw's central height.

The coaxiality of the tailstock gripping jaw is referenced from the loading-end jaw. Its center position is determined by the manufacturing tolerance of the machine frame's opening. The precision of the frame's opening is controlled by machine-tool accuracy.

Furthermore, to ensure the precise center position of the tailstock jaw, guide rollers can be installed on both ends of the tailstock carriage, preventing lateral shifting and ensuring alignment with the loading-end jaw.

The central height of the tailstock jaw is defined by the machining precision of the guide rail tracks and pinhole positions. By adhering to design drawing tolerances, the machining accuracy is ensured, which guarantees that the center height of the tailstock gripping jaw matches that of the loading-end jaw.

In summary, this design guarantees that both the circumferential alignment of the loading-end jaw and the coaxial alignment of the tailstock jaw are maintained along the central axis and height of the machine, ensuring proper coaxiality between the two gripping jaws.

Main Frame Jaw Clamping Mechanism Structure

(Diagram or further elaboration may be added here if applicable)

2. Installation Structure of the Load-Bearing Frame

The guide rails of the load-bearing frame are supported and connected by brackets. These brackets are laid on the support plates and guided using pressing plates with guide grooves. This ensures that the frame and supports remain stable and constrained when subjected to test loads.

The horizontal tension testing machine is installed in a trench-style foundation, with pre-embedded steel plates used for securing the surrounding civil foundation.

Diagram 1 – Load Analysis of Overall Equipment Frame

Diagram 2 – Load Analysis of Overall Equipment Frame

(Note: Actual diagrams should be included or referenced in the final document)

3. Hydraulic Power Unit

The hydraulic system mainly comprises a high-pressure servo motor pump group, low-pressure motor pump group, servo valve manifold, imported direct-acting servo valves, relief valves, servo-following valves, and an oil tank.

The high-pressure section adopts the latest intelligent servo hydraulic system, primarily composed of a Japanese-imported servo motor, a Bosch Rexroth intelligent variable pump (Germany), and a servo driver. This system can adjust flow and pressure output as needed, achieving significant energy savings.

During both the tensile and load-holding phases, no heat is generated, thus eliminating the need for any cooling devices. The tensile speed of the hydraulic system can be adjusted either manually or automatically, and the cylinder supports fast forward and return functions.

The intelligent servo hydraulic system offers more than 75% energy savings compared to conventional systems, significantly reducing test operating costs.

Low noise: The noise level during operation is below 50 dB.

No heat buildup: As oil temperature does not rise, there is no need for a cooling system.

Extended component lifespan: Seals and valves last significantly longer.

Longer oil service life: Operating at room temperature minimizes oil aging, extending oil change intervals to up to two years.

The hydraulic system adopts servo closed-loop control and a combined high-low pressure oil supply mode to meet the requirements for fast forward/return and tension loading. Pumps and valves must be high-response and highly reliable hydraulic components.

The system strictly controls internal leakage, with pressure drop after load-holding maintained within 1% of the set pressure. The overall pump station design saves space and includes overload protection to ensure high safety and reliability for both equipment and operator, reducing risks of unexpected accidents.

 

VII. Electrical System, Control and Measurement System, and Test Software Overview

1. Electrical System

All external sensor cables, limit switch wires, and servo motor wires must be enclosed in black corrugated conduits with high flame resistance, waterproofing, and high mechanical strength.

The installation of the electrical control cabinet must comply with relevant electrical standards. It should withstand environmental vibrations, feature impact protection, and provide effective grounding.

Electrical Control System:

Test operations are integrated into a single control console, allowing one person to operate the machine independently. The system supports constant-rate control of test force and displacement, and the load sensor uses high-precision components.

System Power Supply:

Input voltage: 380V, three-phase five-wire system. The ground wire must use a dedicated ground. Power frequency: 50Hz.

Main Features:

Real-time dynamic display of test force, displacement, and test curves.

Peak holding functions for maximum test force and displacement.

Automatic calculation of mechanical performance parameters and the ability to print a complete test report.

Overload protection.

Capability to store test results for future retrieval and analysis, including curve reanalysis, local zooming, and data re-editing.

Automatic data processing and calculation within memory.

Automatic storage and retrieval of specimen conditions, with option for reconfiguration.

2. NKCK-600 Controller Overview

The NKCK-600 controller is specially developed for use in the testing machine industry. Its hardware design emphasizes high integration and modular architecture, adopting SOC (System-on-Chip) and FPGA (Field-Programmable Gate Array) as core components.

High integration ensures simplified circuitry and high reliability.

Modularity allows grouped program management and strong scalability.

Key Features:

Uses event interrupt technology instead of timers for data acquisition, enabling accurate and reliable sampling. (Timers offer 50ms precision at best, while event interrupts allow real-time synchronized acquisition.)

Simplified and practical interface functions (reduced to 52 functions with enhanced capability).

Supports open-loop testing (useful for identifying and distinguishing equipment faults).

Supports relative and absolute zeroing (absolute zeroing returns to the original code, typically used in dynamic testing machines).

Command sending monitoring.

Configurable sampling frequency.

Automatic setting of test space direction.

Configurable servo valve dead zone and zero position.

Automatic detection of controller ID (unique identifier for each controller).

Online PID tuning.

Manual command transmission.

Chinese-English language switch.

Switchable force unit display.

User-friendly interface, easy for technicians to learn and operate.

3. TestWorld Control and Measurement Software

3.1 Test Information Management and Control System

The testing machine's control computer includes a communication interface with the upper-level host (using TCP/IP protocol). It automatically receives test commands, specimen IDs, steel grade numbers, etc., transmitted from the host. Operators can log specimens, and a serial number is automatically generated for sequential testing (manual selection is also supported). After testing, the results and additional data (e.g., manually measured values) are automatically uploaded to the host system.

Since the system automatically stores data in binary and standard Access database formats, if the host is temporarily unable to receive data, the operator can continue the test by manually inputting sample data. Once the host is functional again, the locally stored results can be re-imported and uploaded.

The system can automatically pre-judge whether test results are valid and compliant (e.g., whether breakage occurred within the gauge length). Invalid or failed results will be flagged in the data.

Test results are retained indefinitely, enabling long-term queries. Administrators or users may back up and remove records periodically (e.g., annually).

Manual specimen registration is also supported, and manually logged test results can be uploaded to the host.

Upload data parameters (e.g., decimal precision, data fields) can be customized as described in the software manual.

3.2 Test Data Acquisition

Specimen information can be manually input or downloaded from the upper-level inspection and testing system. The host system imports this information into the local management software. The testing computer then retrieves it from the remote database. Operators can log the specimen based on on-site conditions and select the corresponding serial number and test parameters.

3.3 Test Data Upload

After each test, results are automatically uploaded from the local computer to the host's management software database. If the host is temporarily unavailable, results are saved locally and uploaded once conditions allow. If any uploads fail, users can manually select the test results and upload them in the required file format. All results can also be saved locally as text files with features for recalculating data and exporting raw data points (e.g., load, elongation, displacement, time) in text format.

Manual registration of test specimens is supported. Data fields and delimiters can be modified or expanded. The format of the uploaded data will conform to the host system's requirements.

Results are automatically saved in both .txt and Access database formats to a specified folder and uploaded to the buyer's designated location (folder or database), with data transfer handled by the seller. The seller will provide the data format for downloads, and the buyer must provide the required upload format.

Data Recording System:

The tensile testing machine shall be equipped with an upper-level computer or a touch LCD screen for parameter settings and real-time monitoring. It should support:

Automatic zeroing and calibration

Smooth and continuous loading/unloading

Automatic load holding

Stepless speed adjustment

Full-process monitoring and data acquisition

Automatic plotting of test curves

Storage of original records and curve images

Printing of test reports

It must comprehensively record the entire tensile testing process and working curves for each steel wire rope.

The system must support real-time display and plotting of various curves such as:

Time vs. Load

Time vs. Displacement

Time vs. Deformation

Displacement vs. Load

Load vs. Strain

Stress vs. Strain

Test force and hydraulic pressure should be displayed simultaneously. In case of equipment malfunction, fault codes should be displayed to assist with maintenance.

3.4 Data Export Formats

Data can be automatically imported into an Oracle database and reformatted as per user requirements.

Data can be exported as Excel files (.xls format).

Data can be imported into standard Access databases.

Data can be exported as text files (.txt format).

All data points from test curves (including load, elongation, displacement, time, etc.) can be exported to Excel.

Note: If users require format changes, our company will provide free customization services.j

Exporting Test Results to Excel Interface

Exporting to Standard Access Database Interface

Exporting Test Process Data to Excel Interface

3.5 Overview of Main Software Functions:

The control system for the tensile testing machine is equipped with a dedicated tensile control program. Based on the test methods and standards provided by the client, corresponding operation programs are developed. The user interface is friendly and highly operable. The software allows for test method modifications by the operator, and settings can be completed in accordance with ISO and GB standards and methods.

Multiple Control Modes: Includes constant load, constant displacement, constant strain loading/unloading, and holding functions.

Preload Setting Function: Supports preload settings, with preload force at 20 kN or other preset values.

Real-Time Display of Test Data: Dynamic display of load, displacement, deformation, time, etc.

Analog Voltage Output and Display: Real-time voltage output and display for load and deformation.

Test Curves: Real-time dynamic display of test curves; axis scales and curve colors are customizable; coordinate parameters auto-adjust with increasing data. Curve overlay is supported-previously tested samples can be selected to view corresponding curves.

Test Condition Settings: Channels for load and deformation can be switched; number of load-bearing samples can be set to calculate the load per sample; analog output and failure judgment conditions can be set.

Automated Test Process Control: Programmable test process control is divided into two stages-preparation and execution. The preparation stage includes preloading; the execution stage is the main test process. Control instructions include: directional movement, positioning, zeroing, loop commands, etc., which can be freely combined to fulfill the test purpose.

Test Data Storage: Data is automatically saved with the test report number as the file name.

Viewing Completed Tests: Previously completed test data can be reopened in the software to review procedures, curves, and result data.

Automatic Failure Judgment During Testing: Test failure conditions can be modified in the software. When the condition is met during testing, the system automatically judges failure and stops the test.

Editable Test Reports: Test report formats can be edited and printed as needed; fixed fields can be pre-filled in the software.

Curve Printing: Any curve or overlay from a group of test samples can be printed.

Test Process Control Programming

Test Curve Settings

Test Condition Settings

Test Report Output

Torque Control Parameter Settings

3.6 Programmable Process Control

The test control program is programmable, allowing for complex test procedures. An unlimited number of control stages can be added, each with a different control mode, including displacement, load, elongation, strain, and stress control. Control parameters for each stage are fully customizable, and transitions between stages are automatic and shock-free. Single or multiple stages can be set to repeat cyclically, with the number of cycles adjustable.

With this method, control models can be preconfigured for different steel grades, allowing the system to automatically load and execute the appropriate model for each material-greatly simplifying the operator's workflow.

Note: The Trial Version of the software has restricted permissions for process control programming. The Research Version is fully open.

Process Control Programming Interface

3.7 Settings Options

Includes the following:

Selection of load sensor

Units for load, strength, elongation, etc.

Selection of displayed and uploaded test data fields

Significant digit rounding (decimal places)

Extensometer settings (supporting multiple extensometers, including longitudinal and transverse types)

Test type selection (tension, compression, bending, shear, etc.)

Input of test parameters during the process

Test Data Output Options Interface

Note: Settings options are restricted in the Trial Version and fully open in the Research Version.

3.8 Creating a New Test Project

Users can utilize the wizard function to create a new test project or load and re-edit an existing one.

Recommendation: Use the steel grade number as the project name. This allows the system to automatically load the appropriate control model and test conditions during subsequent tests, eliminating repetitive settings and simplifying the operator's workflow.

VIII. Overall Product Performance Features

Servo motor used as the oil source for energy efficiency

Programmable test methods: Users can create new methods via the setup wizard tailored to specific test requirements and save them for long-term use

Programmable test reports: Leveraging Excel's powerful capabilities, users can freely design report formats, add custom templates, and automatically import test results and curves into Excel for previewing, printing, or saving as Excel, HTM, or HTML formats

Multiple control modes: Includes displacement control, force control, elongation control, stress control, strain control, constant load (creep), constant strain (relaxation), etc.

Programmable test control: Unlimited control stages, each with independently set control modes and parameters, smooth automatic switching, and customizable looping

Triple-axis curve display: Allows simultaneous display of three different test curves in one plot area, configurable as Tension-Strain, Tension-Displacement, Tension-Time, etc., for intuitive monitoring and analysis

Fully automatic test execution and data recording

Powerful test data management: Enables fast searching, viewing, and deletion of test data in various ways

Automatic analysis and statistical evaluation of results upon test completion

User interface follows standard Windows XP style for intuitive and easy operation

Dedicated database management module

Computer-controlled system with automatic tracking and measurement of force and displacement

Dynamic display of load, loading rate, displacement, time, and test curves

Return-to-origin function for automatic return to initial position

Fast and accurate digital calibration of load and displacement. Each gear has overload protection, full-load protection, and position protection during verification

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